Differential Case Reassembly

Coat the rotating surfaces of the differential side gears with gear oil.

Install the 2 differential side gear thrust washers to the 2 differential side gears.

Install the 2 differential side gears, 2 differential pinions and 2 differential side gear thrust washers to the differential case.

HINT:

Install the 2 differential pinions with the differential pinion thrust washers while turning the differential pinion.

Coat the rotating surface of the No. 1 differential pinion shaft with gear oil.

Install the No. 1 differential pinion shaft to the differential case so that the hole for the differential pinion shaft straight pin is aligned with the hole in the differential case.

Using a pin punch and hammer, tap in the differential pinion shaft straight pin to the differential case.

Using a chisel and hammer, stake the differential case hole.

Hold the differential pinion to the differential case side. Using a dial indicator, measure the differential side gear backlash.

Standard backlash:

0.05 to 0.20 mm (0.0021 to 0.0079 in.)

Standard thrust washer thickness:

Part No.	Mark	Thickness
41361-28230	1	1.00 mm (0.394 in.)
41361-28240	2	1.10 mm (0.0433 in.)
41361-28250	3	1.20 mm (0.0472 in.)
41361-28260	4	1.30 mm (0.512 in.)

Clean the contact surface of the differential case and differential ring gear.

Using a heater, heat the differential ring gear to 90 to 110°C (194 to 230°F).

After the moisture on the ring gear has completely evaporated, quickly install the differential ring gear to the differential case.

Aligning the matchmarks, quickly install the front differential ring gear to the differential case with the 16 bolts.

Torque:

106 N*m{1,080 kgf*cm, 78 ft.*lbf}

Install the drive gear to the differential case.